Heavy Fabrication and Structural Welding

Designed with input from welders, Warrior delivers consistent, reliable operation. It provides superior starts and an extremely smooth and stable arc transfer with excellent weld finishes. A high-duty cycle allows for long runs across a variety of applications. Warrior’s air tunnel design keeps critical electronics free from dirt, oil, and foreign objects, ensuring long-term reliability.

A user-friendly design places all controls – including the power switch – on the front panel. Warrior’s simple and clear user interface makes it easy for anyone to get started welding within a few seconds. The sun-friendly display makes the digital meters easy to read outdoors. A durable external body withstands the elements. Warrior’s IP23 rating is designed to endure harsh outdoor environments. Ergonomically designed handles are built to withstand mechanical hoisting, and double bend 14 ga galvanized steel side panels protect against collisions and drops. It is also generator compatible, making it ideal for remote job sites.

In addition to the Warrior power source, the Warrior Feed 304 is an all-new rugged, user-friendly wire feeder. It features a high-torque 4-roll drive, which gives superior feed even with long GMAW (MIG) guns and better feedability than a 2-roll drive. This feeder includes all the controls needed to get the job done, including remote voltage, gas purge, inch wire, and wire feed speed (WFS), trigger lock, and slow run-in.

The company also has a complete range of PowerCut^® manual plasma cutting systems that are designed with ESAB Plasmarc® technology that makes these machines more powerful and durable than any other machine in their class. All five models of PowerCut machines – PowerCut 400, 700, 900, 1300 and 1600 – make plasma cutting easier and more economical, delivering reliability, high production, and a wide variety of performance features in a lightweight, portable unit.

http://youtu.be/m1-Tgcxk984
A demonstration and overview of the PowerCut 900 manual plasma cutting system.

PowerCut technology is designed to reduce operating costs by using a simplified torch system that significantly reduces wear on parts such as heat shields and swirl rings, and increases the life of consumable parts such as the nozzle and electrode. PowerCut machines often demonstrate less consumable costs per foot cut than any competitive machine. They also deliver high cutting speeds and thickness capabilities, as well as high duty cycle ratings. This combination results in outstanding productivity and performance. Patented torches provide further increased performance and longer consumable life for higher production rates at lower costs. Torches feature a lightweight, ergonomic handle for operator comfort. A large face switch maximizes convenience when wearing welder’s gloves.

Other PowerCut features include quick disconnect torch configuration, blow-back pilot arc start for easy starting on painted and coated metals, and a trigger lock for operator comfort. The package arrives ready to cut with torch connected and front-end parts in place for the ultimate in operator convenience.

PowerCut systems feature built-in state-of-the-art troubleshooting diagnostics to ensure optimal cutting performance and reduced downtime. Featuring longer part life, higher cutting speeds, and a simple torch design, the PowerCut 400 and 700 offer superior cutting performance in a small, affordable package. The PowerCut 900, 1300 and 1600 models provide additional enhanced features, including digital readout display, auto-modes such as gouge, grate and normal modes, extra output voltage required for superior plasma gouging capability, and a Plug-n-Play mechanized option which transform the manual machine into a powerful mechanized system.

The PowerCut family provides cutting capabilities from 3/8 in (9.5 mm) up to 1.5 in (38 mm) with severing capabilities from 1/2 in (12.7 mm) up to1.7 in (44 mm), depending on model.

The company also offers the MechTrac automated gantry system for use in mechanized submerged arc welding (SAW) or gas metal arc welding (GMAW) applications.  The MechTrac gantry uses a unique Integrated Cold Electrode (ICE^TM) welding head that exploits the excess heat from the Twin SAW process to melt an additional non-powered welding electrode. This can result in doubling the productivity in deposition rates and in root welds when compared to single wire welding.

An overview of the MechTrac gantry system being used for submerged arc welding.

The gantry system also features the A2-A6 process controller PEK and A2 welding equipment to form a complete welding station that provides precision welding in an easy-to-use system that is powered by an Aristo® 1000 AC/DC inverter power supply and LAF (DC) power source. Aristo 1000 AC/DC is designed for SAW applications to deliver the best welding performance with the lowest power consumption resulting in more welding per kilowatt hour.

MechTrac is available in four configurations, depending on the size of the workpiece: 68 in (1,730 mm), 83 in (2,100 mm), 94 in (2,500 mm), or 118 in (3,000 mm), measuring leg to leg. All configurations have a standard leg height of 59 in (1,500 mm). The gantry can support a maximum weight of 485 pounds (220 kg). A floor-mounted rail is provided in standard lengths of 188 in (3 m), but can be easily extended. Dual-drive motors are standard.

ESAB Welding & Cutting Products, PO Box 100545, 411 South Ebenezer Road, Florence, SC 29501, 843-669-4411, www.esabna.com.

STRAIGHT OXYFUEL CUTTING TORCH
Victor Technologies^TM (St. Louis, MO) offers its Victor^® ST400 straight torch that incorporates the patented Victor 400 series handle that uses a high strength alloy material for durability and features an ergonomic shape to improve operator comfort. The torch’s three-tube design provides a clearer view of the cutting path, while visual cues on the oxygen and fuel knobs simplify use, enhancing safety.

A testimonial demonstration of the ST400 being used for welding repair.

To simplify use, Victor color-coded the labels for the oxygen and fuel valves for instant identification by indicating directions for open and closed valve positions. “Until now, there was no way for an inexperienced worker to effectively and intuitively identify gas valves,” says John Henderson, the group brand manager at Victor Technologies. “The ST400 torch provides operators with the visual acuity necessary for safe and effective oxy-fuel cutting, even if English isn’t their first language.”

Henderson notes that the design changes help companies cope with the retirement of skilled operators and their need to hire younger, less-experienced workers. The design of the torch also improves durability in situations where tools receive rough treatment. The ST400 is compatible with current 300 series consumables and meets or exceeds performance and durability expectations of a Victor torch.

To simplify use and increase precision, the ST400 provides excellent line-of-sight visibility. Victor accomplished this by departing from its traditional tube-in-tube design to a sleeker three-tube design (oxy-fuel cutting requires three tubes, one each for fuel gas, pre-heat oxygen and cutting oxygen). “Our new tube design optimizes cutting area visibility while providing strength and supporting gas flow rate requirements for tip sizes 000 through 6,” says Henderson. The ST400 uses a universal mixer design and mixes the gases in the head of the torch. Like all Victor torches, it enables operators to use one torch for all fuels (acetylene, propylene, propane, etc.) simply by selecting the correct tips.

“Everyone familiar with the cutting performance of a Victor torch will recognize the superior performance of the new ST400 straight torch,” notes Henderson.

Victor Technologies International, Inc., 16052 Swingley Road, Suite 300, St. Louis, MO 63017, 636-728-3057, www.victortechnologies.com.